Chemical Engineering Design - Elsevier.com

1 Chemical EngineeringDesignPrinciples, Practice and Economicsof Plant and Process DesignSecond EditionGavin TowlerRay SinnottAMSTERDAM BOSTON HEIDELBERG LONDONNEW YORK OXFORD PARIS SAN DIEGOSAN FRANCISCO SINGAPORE SYDNEY TOKYOB utterworth-Heinemann is an imprint of ElsevierButterworth-Heinemann is an imprint of ElsevierThe Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, UK225 Wyman Street, Waltham, MA 02451, USA 2013 Elsevier Ltd. All rights reservedNo part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying,recording, or any information storage and retrieval system, without permission in writing from the Publisher. Details on how to seekpermission, further information about the Publisher s permissions policies and our arrangements with organizations such as the CopyrightClearance Center and the Copyright Licensing Agency, can be found at our book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).

2 NoticesKnowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes inresearch methods, professional practices, or medical treatment may become and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods,compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safetyof others, including parties for whom they have a professional the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/ordamage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods,products, instructions, or ideas contained in the material of Congress Cataloging-in-Publication DataTowler, Gavin Engineering Design : principles, practice, and economics of plant and process Design / Gavin Towler, Ray Sinnott.

3 2nd 978-0-08-096659-5 (hardback)1. Chemical Engineering . I. Sinnott, R. K. II. '5 dc232011044962 British Library Cataloguing-in-Publication DataA catalogue record for this book is available from the British information on all Butterworth-Heinemann publicationsvisit our website by:diacriTech, Chennai, IndiaPrinted in the United States of America12 13 14 15 10 9 8 7 6 5 4 3 2 1 ContentsPreface to the Second Edition..xiHow to Use This ..xvPART 1 PROCESS DESIGNCHAPTER 1 Introduction to Design .. of Design .. Organization of a Chemical Engineering Project.. Documentation.. and Standards.. Factors ( Design Margins).. of Design .. 31 CHAPTER 2 Process Flowsheet Development.. Presentation.. Anatomy of a Chemical Manufacturing , Modification, and Improvement of Commercially-Proven Processes.. of Existing Plants.. of Novel Flowsheets.. Review.. Procedure for Flowsheet Development.. 98 CHAPTER 3 Utilities and Energy Efficient.

4 Recovery.. Stream Combustion.. Networks.. Management in Unsteady Processes.. 158 CHAPTER 4 Process .. Simulation Programs.. of Components.. of Physical Property Models.. of Unit With Recycle.. Optimization.. Simulation.. 243 CHAPTER 5 Instrumentation and Process Control.. P&I Instrumentation and Control.. Control Schemes.. , Safety Trips, and Interlocks.. Process Control.. Control Systems.. 276 CHAPTER 6 Materials of Construction.. for Corrosion Costs.. Used Materials of Construction.. as Materials of Construction for Chemical Plant.. Materials (Silicate Materials).. Coatings.. for Corrosion .. 304 CHAPTER 7 Capital Cost Estimating.. of Capital Cost.. and Purpose of Capital Cost of Magnitude Purchased Equipment Installed Costs: The Factorial Method.. Escalation.. Factors.. Offsite Capital Costs.. Tools for Cost of Cost Estimates.. 352 CHAPTER 8 Estimating Revenues and Production Costs.

5 , Revenues, and Profits.. and Raw Material Prices.. Variable Production Fixed Production Costs.. Revenues and Production Costs.. 385 CHAPTER 9 Economic Evaluation of Projects.. Flows during a Project.. Financing.. and Depreciation.. Methods for Economic Value Methods.. Cost Methods.. Analysis.. Portfolio .. 427 CHAPTER 10 Safety and Loss Prevention.. Hazards.. of Product and Process Safety.. Effect Indices.. and Operability Hazard .. 502 CHAPTER 11 General Site .. Location and Site Selection.. Considerations.. 12 Optimization in .. Design Objective.. and Degrees of of a Single Decision of Two or More Decision Programming.. Integer in Industrial .. 551 PART 2 PLANT DESIGNCHAPTER 13 Equipment Selection, Specification, and Design .. of Equipment Design to Equipment Selection and Design .. 14 Design of Pressure Vessels.. Vessel Codes and Standards.

6 Of Strength of Materials.. Design Considerations for Pressure Vessels.. Design of Thin-Walled Vessels Under Internal Pressure.. for Openings and of Vessels Subject to External of Vessels Subject to Combined Loading.. Flanged Joints.. Joint Assessment of Tests.. Storage Tanks.. 627 CHAPTER 15 Design of Reactors and Mixers.. Design : General Procedure.. of Reaction Engineering Data.. of Reaction .. and Cooling of Reacting Systems.. Reactors.. Design for Catalytic Processes.. of Bioreactors.. Batch Reactors.. Simulation of Actual Reactor Considerations in Reactor Design .. Cost of Reactors.. 750 CHAPTER 16 Separation of Fluids.. Separations.. Liquid Separators.. of Dissolved .. 805 CHAPTER 17 Separation Columns (Distillation, Absorption, and Extraction).. Distillation: Process Description.. Distillation: Basic Principles.. Variables in Distillation.. Methods for Binary Distillation: General Considerations.

7 Distillation: Shortcut Methods for Stage and Distillation: Rigorous Solution Procedures(Computer Methods).. Distillation Processes.. Column Sizing.. Contactors.. Hydraulic Auxiliaries.. Extraction (Liquid Liquid Extraction).. Cost of Separation Columns.. 932 CHAPTER 18 Specification and Design of Solids-Handling Equipment.. of Granular Materials.. and Transport of and Mixing of Separations (Gas Cleaning).. of Solids from of Liquids from Solids (Drying).. Formation, Shaping, and Size Enlargement Processes.. Size Reduction (Comminution).. Transfer to Flowing Solid of Solids .. 19 Heat-Transfer Equipment.. Design Procedure and Theory.. Heat-Transfer Coefficient.. Factors (Dirt Factors).. and Tube Exchangers: Construction Details.. Temperature Difference (Temperature Driving Force).. and Tube Exchangers: General Design Considerations.. Heat-Transfer Coefficient and Pressure Drop (Single Phase).

8 Heat Transfer and Pressure Drop (Single Phase).. and Vaporizers.. Heat Exchangers.. Heat Heat Exchangers.. Heaters (Furnaces and Boilers).. Transfer to Vessels.. Cost of Heat Transfer .. 1191 Nomenclature.. 20 Transport and Storage of Fluids.. of Fluids.. of Gases and Drop in Pipelines.. and Expansion of Gases.. of Liquids.. of Drivers for Rotating Equipment.. Design of Piping Systems.. Size Selection.. of Control .. 1259 Nomenclature.. (visit to download the following appendices)AGraphical Symbols for Piping Systems and Plant..A-1 BCorrosion Property Data Bank.. C-1 DConversion Factors.. 1267 EDesign Projects (Shorter Problem Statements)..E-1 FDesign Projects (Longer Problem Statements)..F-1 GEquipment Specification (Data) Shell and Tube Heat Exchanger Tube-Sheet Layouts.. H-1 IMaterial Safety Data Sheet..I-1 Index..1271xContentsPreface to the Second EditionThis book was originally written by Ray Sinnott as Volume 6 of the Chemical Engineering seriesedited by Coulson and Richardson.

9 It was intended to be a standalone Design textbook for under-graduate Design projects that would supplement the other volumes in the Coulson and Richardsonseries. In 2008 we published the first edition ofChemical Engineering Design : Principles, Practiceand Economics of Plant and Process Designas an adaptation of Coulson and Richardson Volume 6for the North American market. Some older sections of the book were updated and references tolaws, codes, and standards were changed to an American rather than British basis; however, thegeneral layout and philosophy of the book remained first edition of this book was widely adopted and I received a great deal of valuable feed-back from colleagues on both the strengths and weaknesses of the text in the context of a typicalNorth American undergraduate curriculum. The experiences and frustrations of my students atNorthwestern University and comments from coworkers at UOP also helped suggest areas wherethe book could be improved.

10 The changes thathave been made in this second edition are myattempt to make the book more valuable to students and industrial practitioners by incorporatingnew material to address obvious gaps, while eliminating some material that was dated or repetitiveof foundation main change that I have made is to rearrange the order in which material is presented to fitbetter with a typical two-course senior Design sequence. The bookis now divided into two I: Process Design covers the topics that are typically taught in a lecture class. The broadthemes of Part I are flowsheet development, economic analysis, safety and environmental impact,and optimization. Part II: Plant Design contains chapters on equipment Design and selection that canbe used as supplements to a lecture course. These chapters contain step-by-step methods for Design -ing most unit operations, together with many worked examples, and should become essential refer-ences for students when they begin working through their Design projects or face Design problemsearly in their industrial coverage of process flowsheet development has been significantly increased in this introductory chapters on material and energy balances have been deleted and replaced withchapters on flowsheet development and energy recovery, which lead into the discussion of processsimulation.